Flocked transfer and article of manufacturing including the flocked transfer

ABSTRACT

A flocked transfer is produced by applying a release agent to a release sheet and then applying the flocking to the release agent. Unlike the traditional method, a binder and hot melt film is not applied to the back of the flock. The transfer (which is essentially a flocked release sheet) is then applied to a substrate (i.e., an item of clothing, a rubber pad, etc.) by positioning a sheet of thermosetting hot melt film on the substrate; placing the transfer on the hot melt film with the flock in contact with the hot melt film; and applying heat and pressure. The heat melts the thermosetting hot melt film to bind the flock to the substrate and binds the flocking together. This method reduces the costs involved in producing flocked articles, especially for articles produced on a continuous basis.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 09/621,830 filed Jul. 24, 2000. The entire disclosure of theprior application is considered to be part of the disclosure of thepresent application and is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

This invention relates to flocked transfers, and, in particular, to animproved method of making flocked transfers which can reduce the costand time required of producing transfers by a significant amount.

Heretofore, flocked transfers have generally been produced by applying arelease agent to a release sheet. The flocking is applied to the releasesheet in the desired pattern. A binder and a permanent hot melt adhesiveare applied to the back of the flocking, and the transfer is allowed todry. The binder is required hold the flocking in the desired pattern.The hot melt adhesive, which is applied to the transfer as a powder, isused to adhere the transfer to a substrate, such as an article ofclothing, a neoprene pad, etc. The transfer is applied to the substrateby placing the transfer on the substrate with the dried hot meltadhesive in contact with the substrate. Heat, such as from an iron, isthen applied to the release sheet. The heat melts the hot melt adhesiveto cause hot melt adhesive to flow into intimate contact with thesubstrate, forming a mechanical and molecular bond with the substrate.The release agent then allows for the release sheet to be removed fromthe transfer, leaving the flocking exposed on the substrate.

This traditional method has worked well for years. However, the methodcan be improved upon to reduce the cost of producing the transfer, andhence, the cost of the item containing the transfer.

BRIEF SUMMARY OF THE INVENTION

In accordance with the invention, generally stated, a flocked transferof the present invention is produced by applying a release agent to arelease sheet and then applying the flocking to the release agent.Unlike the traditional method, a binder and adhesive are not applied tothe ends of the flock.

To form an article of manufacture with the flocked transfer, athermosetting adhesive film (in the form of a sheet or cut to shape) ispositioned on the substrate to which the transfer is to be applied. Thethermosetting film is preferably a polyester or polyurethane film, butcan be any thermosetting film. The flock with the release adhesive andrelease sheet (i.e., the transfer) is then placed on the sheet ofpermanent adhesive film with the release sheet up, so that the flockingis in contact with the permanent adhesive film. Heat is then applied tothe transfer. The heat melts the permanent adhesive film, and securesthe flock to the substrate. Because the permanent adhesive film isthermosetting, even if it is subsequently subjected to heat, it will notremelt, nor become tacky, and hence, there is no risk of fibers becomingmatted down in any of this type of adhesive, which could otherwise ruinthe plush pile effect. In addition, it is likely that the use of athermoset powder could be added to a bond print latex flock adhesivebinder, to serve as a method for increasing the adhesion and againreducing the risk of any remelting, or becoming tacky, when the flocktransfer is subsequently exposed to heat. It is known that there is amuch stronger adhesion with thermosetting materials, because thermosetmaterials will cross-link with a chemical reaction and thereby adherethe flock fibers to it, which become chemically attached thereto.Through the usage of this invention, the finished flock surface is moreplush, soft, because more of the fiber is exposed and extends upwardlyout of the adhesive, than with the screen-printed latex, as currentlyused. Also, this affords better soil release during washing or cleaningbecause of less fiber/adhesive entanglement occurs with the flock,during application.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a prior art flock transfer;

FIG. 2 is a cross-sectional view of a flock transfer of the presentinvention;

FIG. 3 is an exploded view of the transfer, a permanent adhesive sheet,and a substrate used to make an article of manufacture;

FIG. 4 is a cross-sectional view of an article of manufacture using thetransfer of the present invention, showing a part of the transferapplied to part of the substrate and a part of the transfer andpermanent adhesive film spaced from the substrate; and

FIG. 5 is a schematic drawing of a process for continuously producingarticles of manufacture, such as mouse pads, coasters, etc.

Corresponding reference numerals will be used throughout the severalfigures of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description illustrates the invention by way ofexample and not by way of limitation. This description will clearlyenable one skilled in the art to make and use the invention, includingwhat I presently believe is the best mode of carrying out the invention.

A prior art flocked transfer 101 is shown in FIG. 1. As is known, suchtransfers include a dimensionally stable release sheet 103 to which aconventional flock transfer release adhesive 105 is applied in a patternwhich corresponds to the overall image to be flocked. The flock 107 isthen electrostatically coated into the release adhesive 105. A binderadhesive 109 is applied to the exposed ends of the flock to bind theflock together as a unit. Lastly, a hot melt adhesive film 111 isapplied. The transfer is then allowed to dry. The transfer is applied toa substrate, as is known, by positioning the transfer on a substrate,such as a shirt or other item of clothing, with the hot melt adhesive incontact with the substrate, and applying heat to the transfer. The heatactivates the hot melt adhesive to adhere the transfer to the substrate.

This process is described in my prior patent, U.S. Pat. No. 4,810,549,as well as in my co-pending application, Ser. No. 09/548,839 filed Apr.13, 2000, both of which are incorporated herein by reference. In U.S.Pat. No. 4,810,549, a plush textured multicolored flock is disclosed inwhich differing colors of flock having a length greater than 0.3 mm areapplied sequentially to a release adhesive coated base sheet throughpredetermined areas of masked screens. The applied flock is thereaflercoated with a binder adhesive, such as a liquid water-based acrylic(40-60% water), which binds the flock into a unit. In one configuration,the binder adhesive contains an additional adhesive, such as a hot melt,for binding the transfer to a substrate. In an alternativeconfiguration, the hot melt adhesive (which is usually a granularpolyester or nylon) is formed as a separate layer. U.S. application Ser.No. 09/548,839, filed Apr. 13, 2000, discloses a mouse pad produced byapplying differently colored flock (having a length of 1 mm and 3.3Dtex) electrostatically through a screen to a release adhesive-coatedpaper sheet. A binder adhesive, such as a water-based acrylic, is screenprinted to the flock afler contacting the release adhesive. The binderadhesive may contain a hot melt or the hot melt may be applied to thefree surface of the binder adhesive. The hot melt adhesive is bonded toa surface, such as a rubber pad, using heat and pressure. The releaseadhesive and paper sheet are then removed. In one process configuration,a flock-coated adhesive carrier sheet, a solid pre-formed binderadhesive film or heat seal film, and the rubber base material arethermally fused together in a drying oven.

A flocked transfer 1 of the present invention is shown in FIG. 2. Thetransfer 1 of the present invention includes a release sheet 3 to whicha conventional release agent, such as wax, has been applied. The releaseagent is applied to the sheet in the shape of the pattern of theflocking. Flocking 7 is then applied to the release agent, and hence tothe release sheet, to form the transfer. The flocking 7 is applied, forexample, in the manner as described in my prior patent, U.S. Pat. No.4,810,549, which is incorporated herein by reference. Unlike the priorart processes, the transfer 1 of this embodiment is made without the useof a binder adhesive or a hot melt adhesive. As is discussed below, athermosetting film is used to adhere the transfer to a substrate.

With reference to FIG. 3, an article of manufacture, such as an item ofclothing having a transfer 1 applied thereto, a mouse pad, coaster, orother item having a flocked surface is easily produced using thetransfer 1. The article of manufacture 11 is produced by positioning ahot melt or thermosetting permanent adhesive sheet 13 between asubstrate 15 and the flocked release sheet. The sheet is, for example, asheet of thermosetting polyester, available from Bostik, Inc. The sheetcan also be made from a thermosetting polyurethane. Any otherthermosetting film should also work well. The substrate can be an itemof clothing, a rubber pad (for producing a mouse pad or coaster), etc.The sheet can be precut to correspond to the shape of the transfer 1.The transfer 1 is then positioned on the sheet with the flock 7 againstthe sheet 13. Heat is applied to the transfer through the release sheetto activate the permanent adhesive sheet. The sheet then acts to bothbind the flock 7 together and to adhere the flock 7 to the substrate 15.Preferably, to assemble the article, the flocked release sheet, thepermanent adhesive sheet (which is preferably the thermosetting film),and the substrate are brought together and passed through aheat-laminating press where the three parts are subject to temperatureof about 300° F. (about 150° C.) and pressure (about 40-50 psi) forabout 30 seconds. It has been found that a medium-to-firm pressure hasbeen most advantageous in providing for assembly of this type of plushflocked transfer. The pressure and heat will cause the permanentadhesive sheet to adhere to the flock and the substrate. Additionally,the thermosetting film will cross-link or cure, to give a strongattachment of the flock to the substrate.

Articles, such as mouse pads or coaster, in which the entire top surfaceof the article is covered with the flocking can be produced on acontinuous basis, as shown in FIG. 5. Rolls 21, 23, and 25 of a flockedrelease sheet 1, the permanent adhesive sheet 13, and the substrate 15are provided. The three parts are brought together at a laminatingstation 33. Rollers can be provided in front of the station 33 so thatthe three elements are adjacent each other as they enter the laminatingstation. In the laminating station, heat and pressure are applied to thethree sheets (the flocked release sheet, the permanent adhesive sheet,and the substrate) to melt the permanent adhesive sheet. The meltedpermanent adhesive sheet will then cure or cross-link, as noted above,to adhere the flock to the substrate. A web 35 exits the laminatingstation. The web 35 is then allowed to cool. The web 35 is ultimatelydirected to a cutting station where it is cut into individual articles.Once the web 35 is cooled, it can be directed immediately to a cuttingstation (after the sheet 35 cools), or can it can be wound up on anuptake roller to be cut into individual articles at a later time, or ata different location. At the cutting station, the release sheet isremoved from the flock and gathered on an uptake roll or is otherwisedisposed of. After the release sheet has been removed from the flock,the substrate with the flock adhered thereto is cut to form the articles11. It is also likely that one could remove the release liner eitherbefore or after the die cutting procedure.

Preferably, the release sheet is flocked and supplied in roll form asshown in FIG. 5. However, the flocking of the release sheet could bemade part of the process.

To produce flocked articles, such as shirts, jackets, etc., which cannotbe easily flocked on a continuous basis, the permanent adhesive sheetcan be applied to the transfer 1 prior to applying the transfer to thesubstrate. To do this, the thermosetting film is placed in contact withthe flock of the transfer, and the transfer and release sheet are heatedto a temperature at which the thermosetting film become tacky, but belowthe temperature at which the thermosetting film begins to cure andcross-link. This will adhere the thermosetting film to the transfer 1 toform a transfer which can later be applied to an article by positionedthe transfer with the thermosetting film in position on the article(i.e., piece of clothing) and applying heat and pressure to thetransfer, for example, with an iron, sufficient to melt thethermosetting film, to cause the film to cure and cross-link.

The method eliminates two steps from the prior art method: (1)application of the binder adhesive and (2) application, cleaning,sintering, and drying of the hot melt adhesive. In a continuous process,the present method also eliminates a station for applying the binder andhot melt adhesives as well as a station for drying the completedtransfer. Because a station is not needed to apply (i.e., print) thebinder and hot melt adhesives to the flocking as part of the transfer,the machinery required to produce the article 11 is much less expensive(both in actual costs and in maintenance costs). Additionally, becausethe binder adhesive and hot melt adhesive is not used, the cost of thearticle of manufacture is significantly reduced.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

1. A flocked assembly, comprising: flock, said flock comprised of firstends and opposing second ends; a pre-formed, solid, and self-supportingthermosetting film, wherein substantially all opposing second ends arein contact with and adhered to the thermosetting film; and wherein thethermosetting film is: free of a binder adhesive positioned between thethermosetting film and flock; of substantially uniform thickness;substantially flat upper and lower surfaces; and is not adhered to asubstrate.
 2. A transfer comprising the flocked assembly of claim
 1. 3.The flocked assembly of claim 2, wherein said first ends of said flockare adhered to a release sheet by a release agent and wherein thethermosetting film contacts said opposing second ends of the flock. 4.The transfer of claim 3, wherein the transfer is free of an acrylicadhesive.
 5. The transfer of claim 4, wherein said second ends of theflock are embedded in the thermosetting film and wherein thethermosetting film comprises a thermosetting polyester.
 6. The flockedassembly of claim 1, wherein the thermosetting film is a thermosettingpolyurethane film or a thermosetting polyester film.
 7. The flockedassembly of claim 1, wherein the thermosetting film is precut tocorrespond to a shape of the transfer and wherein the thermosetting filmis a thermosetting polyurethane.
 8. The flocked assembly of claim 3,wherein the release agent and release sheet are located on a firstsurface of the flock and the thermosetting film is positioned on asecond surface of the flock and the first and second surfaces are in anopposing relationship.
 9. The flocked assembly of claim 1, wherein thereis no hot melt thermoplastic adhesive located between the thermosettingfilm and the flock.
 10. The flocked assembly of claim 1, wherein thethermosetting film is not fully crosslinked.
 11. The flocked assembly ofclaim 1, wherein the flock is in direct physical contact with thethermosetting film.
 12. The flocked assembly of claim 1, wherein thethermosetting film is not fully activated.
 13. The flocked assembly ofclaim 1, wherein the thermosetting film is continuous.
 14. A flockedassembly, comprising: flock; and a solid, self-supporting thermosettingfilm, wherein the flock is in contact with and adhered to thethermosetting film, wherein there is no intermediate adhesive positionedbetween the thermosetting film and flock and wherein the thermosettingfilm is not adhered to a substrate.
 15. The flocked assembly of claim14, wherein said flock comprised of first ends and opposing second ends,wherein the thermosetting film is pre-formed and self-supporting,wherein substantially all second ends of the flock physically contactthe thermosetting film, and wherein the thermosetting film has asubstantially uniform thickness and substantially flat upper and lowersurfaces.
 16. The flocked assembly of claim 14, further comprising: arelease sheet; and a release agent in contact with the release sheet,wherein first ends of said flock are adhered to the release sheet by therelease agent and wherein the thermosetting film contacts opposingsecond ends of the flock.
 17. The flocked assembly of claim 16, whereinsaid second ends of flock are not in contact with a hot melt binderadhesive.
 18. The flocked assembly of claim 17, wherein thethermosetting film comprises a thermosetting polyester and wherein thethermosetting film is not in contact with an acrylic or a hot meltthermoplastic adhesive.
 19. The flocked assembly of claim 18, whereinthe thermosetting film is a thermosetting polyurethane film or athermosetting polyester film.
 20. The flocked assembly of claim 14,wherein the flocked assembly is a transfer, wherein the thermosettingfilm is precut to correspond to a shape of the transfer, and wherein thethermosetting film is a thermosetting polyurethane.
 21. The flockedassembly of claim 14, wherein the thermosetting film is not fullycrosslinked.
 22. The flocked assembly of claim 14, wherein there is noacrylic or hot melt thermoplastic binder adhesive located between thethermosetting film and the flock.
 23. The flocked assembly of claim 14,wherein the flock is in direct physical contact with the thermosettingfilm.
 24. The flocked assembly of claim 14, wherein the thermosettingfilm is not fully activated.
 25. The flocked assembly of claim 14,wherein the flock is embedded in the thermosetting film.
 26. A flockedassembly, having: flock; and a self-supporting thermosetting film thatis not adhered to a substrate and acts as the adhesive for the flock,wherein there is no binder adhesive located intermediate to saidthermosetting film and said flock.
 27. The flocked assembly of claim 26,wherein said flock is comprised of first ends and opposing second ends,wherein the thermosetting film is a pre-formed solid, whereinsubstantially all second ends of the flock contact the thermosettingfilm, and wherein the thermosetting film has a substantially uniformthickness and substantially flat upper and lower surfaces.
 28. Theflocked assembly of claim 26, further having: a release sheet; a releaseagent in contact with the release sheet, wherein first ends of saidflock are adhered to the release sheet by the release agent; and whereinthe thermosetting film: contacts opposing second ends of the flock,comprises a thermosetting polyester, and is not in contact with anacrylic or a hot melt thermoplastic adhesive.
 29. The flocked assemblyof claim 26, wherein the thermosetting film is a thermosettingpolyurethane film or a thermosetting polyester film.
 30. The flockedassembly of claim 26, wherein the flocked assembly is a transfer,wherein the thermosetting film is precut to a shape of the transfer, andwherein the thermosetting film is a thermosetting polyurethane.
 31. Theflocked assembly of claim 26, wherein the thermosetting film is notfully crosslinked.
 32. The flocked assembly of claim 26, wherein thereis no acrylic or hot melt thermoplastic binder adhesive located betweenthe thermosetting film and the flock.
 33. The flocked assembly of claim26, wherein the flock is in direct physical contact with and embedded inthe thermosetting film.
 34. The locked assembly of claim 26, wherein thethermosetting film is not fully activated.